Assembling Machine with Continuous Peak Assembly Motion

ABSTRACT

An assembling machine with a feeder is provided. The feeder feeds receiving components into an assembler, where a moveable coupling mechanism couples attaching components to the receiving components. Transporting mechanisms coupled to a plurality of drive trains deliver the receiving components across the feeder table and to the assembler. The transporting mechanisms alternate between a plurality of speeds so as to deliver the receiving components to the assembler such that the moveable coupling mechanism may operate at a continuous, periodic rate.

CROSS REFERENCE TO PRIOR APPLICATIONS

This application is a divisional application under 35 USC §121 of U.S.application Ser. No. 11/415,561, filed May 2, 2006, which isincorporated by reference for all purposes.

BACKGROUND

1. Technical Field

This invention relates generally to an assembling machine having anassembler that couples a first component to a second component, and morespecifically to an assembling machine, for example a partition insertionmachine, having a moving assembler, where a feeder is capable of feedingcomponents to the assembler such that the moving assembler may operatein a continuous periodic motion.

2. Background Art

The assembly of components has long been automated. From assemblingenvelopes to automobiles, most repetitive work in factories today isaccomplished by machines. In many factories, a conveyor belt feedsunfinished components to a task-performing machine. Upon receiving theunfinished component, the task-performing machine executes itsprogrammed function. The machine then waits as the conveyor belt movesthe completed component down the line. When a new unfinished componentreaches the machine, the programmed task is executed again. This processcontinues, with the machine working and waiting, for as long as the lineis operational.

By way of example, consider a machine for assembling packagingpartitions. When viewed in cross section, these partitions—which areoften made of cardboard and separate items or components in a box toprevent them from touching—often resemble a multi-celled tic-tac-toeboard made of vertical components inserted into horizontal components. Amachine performs the step of insertion. By way of example, a worker maydeliver a set of vertical components to the assembler. With arat-tat-tat motion, the assembler inserts the horizontal components intothe vertical components. The assembler then stops, to allow the workerto clear the completed partition assembly from the assembler. Theassembler waits for another set of vertical components to be delivered.Once the vertical components are in place, the assembler again attachesthe horizontal components.

There are two problems with such partition assemblers: first, they areexpensive and inefficient to operate. A worker must deliver parts to theassembler, activate it, stop it, and then remove the assembly. Second,stopping and starting the machine causes wear and tear. This is becausethe majority of wear and tear on automated machines occurs not when theyare running, but when they are stopped and restarted.

There is thus a need for an improved assembly machine that is moreefficient.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying figures, where like reference numerals refer toidentical or functionally similar elements throughout the separate viewsand which together with the detailed description below are incorporatedin and form part of the specification, serve to further illustratevarious embodiments and to explain various principles and advantages allin accordance with the present invention.

FIG. 1 illustrates a perspective view of one example of a semi-assembledpartition suitable for assembly with a machine in accordance with theinvention.

FIG. 2 illustrates a general view of one embodiment of an assemblymachine in accordance with the invention.

FIG. 3 illustrates one embodiment of a method executed by a calibrationdevice in accordance with the invention.

FIG. 4 illustrates a perspective view of partitions being assembled withan assembly machine in accordance with the invention.

FIGS. 5-7 illustrate time-lapse views of partitions being assembled withan assembly machine in accordance with the invention.

FIG. 8 illustrates an elevation side view of one embodiment of anassembly machine in accordance with the invention.

FIG. 9 illustrates a front elevation view of one embodiment of a drivetrain assembly in accordance with the invention.

FIG. 10 illustrates a rear elevation view of one embodiment of a drivetrain assembly in accordance with the invention.

FIG. 11 illustrates a top plan view of one embodiment of a feeder tablein accordance with the invention.

Skilled artisans will appreciate that elements in the figures areillustrated for simplicity and clarity and have not necessarily beendrawn to scale. For example, the dimensions of some of the elements inthe figures may be exaggerated relative to other elements to help toimprove understanding of embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Before describing in detail embodiments that are in accordance with thepresent invention, it should be observed that the embodiments resideprimarily in combinations of method steps and apparatus componentsrelated to automatically assembling components by way of an assemblymachine. The apparatus components and method steps have been representedwhere appropriate by conventional symbols in the drawings, showing onlythose specific details that are pertinent to understanding theembodiments of the present invention so as not to obscure the disclosurewith details that will be readily apparent to those of ordinary skill inthe art having the benefit of the description herein.

Embodiments of the invention are now described in detail. Referring tothe drawings, like numbers indicate like parts throughout the views.Relational terms such as first and second, top and bottom, and the likemay be used solely to distinguish one entity or action from anotherentity or action without necessarily requiring or implying any actualsuch relationship or order between such entities or actions. As used inthe description herein and throughout the claims, the following termstake the meanings explicitly associated herein, unless the contextclearly dictates otherwise: the meaning of “a,” “an,” and “the” includesplural reference, the meaning of “in” includes “in” and “on.” Also,reference designators shown herein in parenthesis indicate componentsshown in a figure other than the one in discussion. For example, talkingabout a device (10) while discussing figure A would refer to an element,10, shown in figure other than figure A.

Described herein is an assembly machine configured to deliver areceiving component to an assembler having a moveable couplingmechanism. The moveable coupling mechanism, which couples attachingcomponents to the receiving components, does so at a continuous periodicrate. A feeder is configured with multiple drive trains, each of whichis capable of altering its speed along a drive train path. The drivetrains have transporting mechanisms coupled thereto. The transportingmechanisms cause the receiving components to move along the feeder tothe assembler. In one embodiment, the drive trains, and thus theattached transporting mechanisms, alter speed along the drive train pathso as to deliver the receiving components to the assembler such that theassembler may operate continuously without stopping between the deliveryof a first receiving component or components and the delivery of asecond receiving component or components. As such, the assembly machineof the present invention, using the feeder with multiple drive trains,each capable of altering its speed individually, operates moreefficiently than prior art assembly machines. Experimental testing hasshown the assembly machine of the present invention to increasethroughput as much as 50% over prior art machines.

Throughout this disclosure, assembly of partitions will be set forth asone exemplary application for an assembly machine in accordance with theinvention. This example is used for simplicity and clarity inexplanation. Further, experimental testing has shown that an assemblymachine in accordance with the invention is well suited for such anapplication. It will be clear to those of ordinary skill in the arthaving the benefit of this disclosure, however, that embodiments of thepresent invention are not limited to such applications. The inventionmay be applied to a wide variety of assembly applications wherecomponents are coupled together or where an insertion step occurs.Accordingly, the specification and figures are to be regarded in anillustrative rather than a restrictive sense, and all such modificationsare intended to be included within the scope of present invention. Thebenefits, advantages, solutions to problems, and any element(s) that maycause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as a critical, required, or essentialfeatures or elements of any or all the claims.

Turning now to FIG. 1, illustrated therein is one embodiment of asemi-assembled partition 100 suitable for assembly by an assemblingmachine in accordance with the invention. This exemplary partition 100may be referred to as a “two by three” partition or a “three by fourcell” partition. The partition 100 includes two receiving components101,102, which are akin to the vertical components mentioned above, asthey appear vertical when the partition 100 is viewed in cross section.The receiving components 101,102 are on the bottom of the partition 100,and include various notches, e.g. 106, suitable for receiving othercomponents.

The partition 100 includes three attaching components 103,104,105, whichcomprise the horizontal components mentioned above, as they appear to behorizontal when the partition 100 is viewed in cross section. Eachattaching component 103,104,105 includes a notch or recess, e.g. 107,suitable for coupling to other components. During assembly, for example,notch 106 of receiving component 101 engages notch 107 of attachingcomponent 103. The other notches do so likewise, thereby forming thetic-tac-toe cross section commonly associated with the partition 100.

Turning now to FIG. 2, illustrated therein is one embodiment of anassembly machine 200 in accordance with the invention. The assemblymachine 200 includes a feeder 201 configured to deliver receivingcomponents 207,208 (or groups of receiving components) to an assembler202. The assembler 202 is configured to couple an attaching component206 to the receiving components 207, 208 by way of a moveable couplingmechanism 205. The moveable coupling mechanism 205 moves reciprocally ina periodic motion while the receiving components 207,208 pass beneath.When a particular notch 224 is aligned with the attaching component 206,the moveable coupling mechanism 205 couples the attaching component 206with the receiving components 207.

In prior art systems, there is a time delay between delivery ofreceiving component 207 and delivery of receiving component 208. Thus,the moveable coupling mechanism 205 must pause between the last notch218 of the first receiving component 207 exiting the assembler 202 onconveyer belt 216 and the first notch 219 of the second receivingcomponent 208 being delivered to the assembler 202. This pause orstoppage reduces throughput and efficiency.

With the present invention, by contrast, the feeder 201 includes aplurality of drive trains 212,213. Each drive train 212,213 includes atleast one transporting mechanism coupled thereto. For instance,transporting mechanism 209 is coupled to drive train 213, whiletransporting mechanism 210 is coupled to drive train 212. Thetransporting mechanisms 212,213 are configured to feed the receivingcomponents 207,208 into the assembler 202, beneath the moveable couplingmechanism 205, and onto conveyer belt 216.

In accordance with one embodiment of the invention, the drive trainspeed of each drive train 212,213 changes such that the moveablecoupling mechanism 205 may continue to operate reciprocally at aconstant, periodic coupling rate. In other words, the drive trains212,213 alter speeds along the respective drive train loop so as todeliver the notches 217,218,219 of the receiving components 207,208 tothe assembler 202 at a constant rate. This constant rate allows themoveable coupling mechanism 205 to reciprocate continually and evenly ata constant rate. On the upstroke the moveable coupling mechanism 205retrieves an attaching component 206. On the down stroke, the moveablecoupling mechanism 205 inserts the attaching component 206 into a notchof a receiving component. In the exemplary FIG. 2, drive train 212accelerates at specific moments so as to deliver notch 219 to theassembler 202 after notch 218, in the same elapsed time that transpiresbetween the delivery of notch 220 and notch 219. Said differently, thedrive train speed associated with one of the plurality of drive trains,i.e. the drive train speed of drive train 212, changes such that theperiodic coupling rate of the moveable coupling mechanism 205 remainsconstant between attachment of a first attaching component with a firstreceiving component, i.e. the attaching component coupled to notch 218of receiving component 207, and attachment of a second attachingcomponent with a second receiving component, i.e. the attachingcomponent coupled to notch 219 of receiving component 208. This periodiccoupling rate of attaching components to receiving components will beshown in more detail in the discussion of FIGS. 4-6 below.

As noted above, the exemplary application set forth in FIG. 2 is that ofa partition-assembling machine where attaching components are insertedinto receiving components. In such an application, the assembler 202effectively becomes an insertion assembly, as the attaching componentsare “inserted” into the notches of the receiving components. Thus, theattaching component, e.g. 206, may also be referred to as an insertingcomponent. Where the assembly machine 200 is configured to constructpartitions like those shown in FIG. 1, a multi-celled partition, theinsertion assembly is configured to insert a plurality of insertingcomponents into one or more receiving components.

The feeder 201 includes a feeder table 221 configured to deliver one ormore receiving components 207,208 to the assembler 202. The feeder 201includes a feeder table 221 employing at least two drive trains 212,213to accomplish the delivery. The drive trains 212,213 each have one ormore transporting mechanisms 209,210,226 coupled thereto. For example,drive train 212 is coupled to transporting mechanism 210, while drivetrain 213 is coupled to transporting mechanism 209. When the drivetrains 212,213 move, so do the transporting mechanisms 209,210, therebydelivering the receiving components 207,208 to the assembler.

In one embodiment, the drive trains 212,213 employ a pair of chaindriven loops 214,215 to move the transporting mechanisms 209,210. Forexample, drive train 212 employs chain 214, while drive train 213employs chain 215. Transporting mechanism 209, being coupled to chain215, moves when drive train 213 moves chain 215. Correspondingly,transporting mechanism 210, being coupled to chain 214, moves when drivetrain 212 moves chain 214.

In viewing FIG. 2, the receiving components 207,208 move right to left,flowing from the delivery module 203 to the assembler 202. The moveablecoupling mechanism 205 moves vertically in a reciprocating motion so asto insert the attaching components, e.g. 206, into the receivingcomponents 207,208. Thus, the feeder 201 feeds the receiving components207,208 into the assembler 202 in a first direction 222. The moveablecoupling mechanism 205 moves in a second direction 223, which intersectsthe first direction, thereby enabling the attachment or insertion.

As the receiving components 207,208 include a plurality of notches, e.g.224, they may be thought of as graduated components, where the notchesserve as the graduations. When, for example, transporting mechanism 209causes the “graduated” receiving component 207 to pass along one side ofthe feeder table 221 into the assembler 202, it must do so with astair-stepped speed. In other words, transporting mechanism 209 pausesmomentarily while the moveable coupling mechanism 205 inserts attachingcomponent 206 into notch 224. The transporting mechanism 209 then movesso as to cause notch 220 to align with the moveable coupling mechanism205. The transporting mechanism 209 then pauses again while anotherattaching component is inserted. This stair-stepped action continuesuntil attaching components have been inserted into each of the notches217,220,218 of receiving component 207.

At this time, transporting mechanism 210 accelerates to ensure thatnotch 219 is aligned with the moveable coupling mechanism 205 on by itsnext downward pass in its periodic coupling rate. Transporting mechanism210 then enters a stair-stepped speed while attaching components arebeing inserted into the notches, e.g. 219, of receiving component 208.

Once the receiving components have been delivered to the assembler, thetransporting mechanisms 209,210 may then move at a faster speed toreturn to the delivery module 203. In the delivery module 203, thetransporting mechanisms 209,210 receive new receiving components 225.For instance, delivery mechanism 217 delivers receiving component 225 tothe feeder table 221 such that it may be delivered to the assembler 202by transporting mechanism 226.

In one embodiment of the invention, each of the drive trains 212,213 hasat least two transporting mechanisms coupled thereto. By way of example,drive train 213 has both transporting mechanism 209 and transportingmechanism 226 coupled to its drive train chain 215. Thus, whiletransporting mechanism 209 is delivering receiving component 207 to theassembler 202, transporting mechanism 226 is nearly in position toaccept receiving component 225.

Coordination of the multiple drive trains 212,213, as well as controlover the varying speed of each drive train chain 214,215, in oneembodiment is coordinated with a computer 204. The computer 204 receivesinput from each of the components, including the assembler 202, thefeeder 201, and the delivery module 203. For instance, the feeder 201includes a transporting mechanism detector 211 that is capable ofdetermining the position of the transporting mechanisms 209,210,226 atleast once along its corresponding drive train loop. In one embodiment,where the transporting mechanisms are manufactured from rigid metal asrigid arms coupling the pair of variable speed servo driven drive trains212,213 for example, the transporting mechanism detector may be amagnetic or optical sensor capable of determining when the transportingmechanism is passing beneath.

Similarly, as will be shown in more detail in the discussion of FIG. 7,each of the drive trains 212,213, as well as the moveable couplingmechanism 205 and the delivery mechanism 217, is driven by a variablespeed servo. Variable speed servo devices include communication systemscapable of telling computer 204 in exactly what position they are inradially. Where computer 204 is programmed with the distance between thetransporting mechanism detector 211 and the moveable coupling mechanism205, and where computer 204 is able to determine the positions of theservos driving the drive trains 212,213, the moveable coupling mechanism205 and the delivery mechanism 217, the computer 204 may serve as acalibration device. As a calibration device, the computer 204 ensuresthat the notches of the receiving modules are delivered at appropriatetimes to the moveable coupling mechanism 205 so as to allow the moveablecoupling mechanism to move at its continuous, periodic rate.Specifically, the computer 204 can adjust the drive train speed of drivetrain 212 so as to minimize the distance between components driven bythe second transporting mechanism coupled to the second drive train,i.e. receiving component 208 driven by transporting mechanism 210coupled to drive train 212, and the first transporting mechanism coupledto the first drive train, i.e. transporting mechanism 209 coupled todrive train 213. This minimization of distance, which occurs when boththe first transporting mechanism and the second transporting mechanismare transporting receiving components, allows notch 219 to align withthe moveable coupling mechanism 205 after notch 218 without altering theperiodic coupling rate of the moveable coupling mechanism 205.

Turning now to FIG. 3, illustrated therein is one such method that thecomputer (204) may execute when operating as a calibration device. Themethod, which may be embodied as computer useable instructions in theform of software code, facilitates a drive train loop and moveablecoupling mechanism action that recurs repeatedly without error ortolerance build up.

At step 301, the computer (204) determines a first feeder position ofthe first transporting mechanism (209), which is coupled to the firstdrive train, i.e. drive train 213. The computer (204) does this bydetermining how far the servo driving drive train 213 has rotated sincethe first transporting mechanism (transporting mechanism 209) passedbeneath the transporting mechanism detector (211). With knowledge of thegear ratios associated with drive train 213, the computer executes asimple calculation to determine the position of transporting mechanism210.

At step 302, the computer (204) detects a second feeder position of thesecond transporting mechanism (transporting mechanism 210), which iscoupled to the second drive train (drive train 212). The computer (204)accomplishes this by sensing transporting mechanism 210 as it passesunder the transporting mechanism detector (211).

At step 303, the computer (204) detects the servo position of the servodriven moveable coupling mechanism (205), which is moving at a constantperiodic coupling rate. This detection allows the computer to determinewhere along the reciprocating stroke the moveable coupling mechanism(205) happens to be.

At step 304, after executing steps 301,302,303, the computer (204)adjusts the drive train speed of the second drive train (drive train212) such that the distance between the first transporting mechanism(209) and components driven by the second transporting mechanism (210)is minimized prior to delivery of the components driven by the secondtransporting mechanism (210) to the moveable coupling mechanism (205).This process is known as “queuing”, and allows the elapsed time betweena penultimate notch and a last notch in a particular receiving componentpassing under the moveable coupling mechanism (205) to be the same asthe elapsed time between the last notch in one receiving component andthe first notch of another receiving component passing under themoveable coupling mechanism (205). In prior art systems, where receivingcomponents were evenly spaced along a feeder, this was not possible. Inthe present invention however, after minimizing the distance, thecomputer (204) is able to adjust the drive train speed of the seconddrive train loop (drive train 212) such that the coupling regions(224,220,218) on receiving components (207) driven by the firsttransporting mechanism (209) and coupling regions (e.g. 219) onreceiving components (208) driven by the second transporting mechanism(210) are delivered to the servo driven moveable coupling mechanism(205) at a constant rate.

At step 305, the computer (204) determines a delivery position of theservo driven moveable delivery mechanism (217). The computer (204) doesthis by detecting the position of the servo driving the deliverymechanism (217). Once this is known, the computer (204) may adjust thedrive train speed of, for example, the first drive train loop (drivetrain 213) such that a drive train transporting mechanism (transportingmechanism 226) engages a receiving component (225) when delivered by themoveable delivery mechanism (217) at step 306.

Turning now to FIG. 4, illustrated therein is a perspective view of oneembodiment of an assembly machine 200 in accordance with the invention.As shown in FIG. 2, the feeder 201 delivers receiving components 207,208to the assembler 202 for assembly. Specifically, transporting mechanism209 delivers receiving member 207, which in some applications mayinclude a plurality of receiving members, to the assembler 202 so thatthe moveable coupling mechanism 205 may insert attaching members206,401,402 into receiving member 207, thereby constructing amulti-celled partition. Similarly, transporting mechanism 210 feedsreceiving members 208,407 to the assembler 202. When notch 219 isaligned with the moveable coupling mechanism 205, attaching members willbe inserted. Completed partitions 403 are then swept away by theconveyor belt 216.

The feeder table 221 is more visible in the perspective view of FIG. 4than in the side view of FIG. 2. As can be seen in FIG. 4, the feedertable 221 includes a plurality of receiving component guides404,405,406. These receiving component guides 404,405,406, in oneembodiment, are rigid slots that run the length of the feeder table 221.Where the assembly machine 200 of the present invention is used inapplications such as partition construction, the receiving componentguides 404,405,406 allow the receiving components 208,407 to move alongthe feeder table 221 in an upright position.

In the exemplary embodiment of FIG. 4, the transporting mechanisms209,210 are disposed substantially perpendicularly to the plurality ofreceiving component guides 404,405,406. This perpendicular alignmentallows a single transporting mechanism 210 to move a plurality ofreceiving components, e.g. 208,407, along the plurality of receivingcomponent guides 404,405,406 at the drive train speed. In this exemplaryembodiment, the transporting mechanisms 209,210 are rigid arms spanningand coupling the chains of their respective drive trains. Note that inFIG. 4 drive train cover 408 covers the drive trains, which in oneembodiment are variable speed servo driven chains coupled to thetransporting mechanisms 209,210.

Turning now to FIGS. 5, 6 and 7, illustrated therein are time-lapse sideviews of the motion of the drive trains 212,213, the transportingmechanisms 209,210, and the receiving members 507,508. For simplicity,FIGS. 5, 6, and 7 illustrate receiving members 207,208 having a singlenotch 518,519. However, as shown in FIG. 1, many applications willinclude receiving members having a plurality of notches. The singlenotch example is to be used for illustration purposes, as it will beclear to those of ordinary skill in the art having the benefit of thisdisclosure that the invention is not to be limited by the illustrationsof FIGS. 5, 6, and 7.

Each of the drive trains 212,213 has at least one transporting mechanism209,210 coupled thereto. For example, drive train 212 is coupled totransporting mechanism 210, while drive train 213 is coupled totransporting mechanism 209. In one embodiment of the invention shown towork well in experimental testing, each drive train 212,213 has at leasttwo transporting mechanisms coupled thereto, with each of thetransporting mechanisms being disposed at substantially equidistantintervals along the drive trains. (In one embodiment two transportingmechanisms per drive train are employed.) Also, in one embodiment thetransporting mechanisms 209,210 are coupled to the drive trains 212,213in a variable speed servo driven loop, with chain 214 and chain 215serving as the loops. Thus, the drive trains 212,213 may be a pair ofchain driven loops having two transporting mechanisms coupled thereto.

At FIG. 5, transporting mechanism 209 delivers receiving component 507to the assembler 202. Moveable coupling mechanism 205 inserts attachingcomponent 506 to receiving component 507 at notch 518. During this time,drive train 213, and thus transporting mechanism 209, moves in a firstdrive train motion that is stair-stepped and intermittent. Thestair-stepped motion continues until the moveable coupling mechanism 205has inserted attaching components into each notch. Drive train 213pauses while moveable coupling mechanism 205 inserts the attachingcomponent 506, and them moves quickly to align the next notch with themoveable coupling mechanism 205.

While this occurs, drive train 212 moves in a second drive train motionhaving a first speed. This first speed allows transporting mechanism 210to cause receiving component 508 to catch up to transporting mechanism209. Drive train 212 adjusts to the first speed such that the distance501 between the first transporting mechanism, transporting mechanism209, and components driven by the second transporting mechanism, i.e.receiving component 508 driven by transporting mechanism 210, isminimized prior to the delivery of the receiving component 508 to theassembler 202 and the moveable coupling mechanism 205. This minimizationallows the moveable coupling mechanism 205 to operate at a continuousperiodic rate even though multiple receiving mechanisms 507,508 passbeneath. In other words, the drive train 212 changes its drive trainspeed such that the periodic coupling rate of the moveable couplingmechanism 205 remains constant between the attachment of a firstattaching component 506 with a first receiving component and theattachment of a second attaching component (element 606 in FIG. 6 below)with the second receiving component 508.

At FIG. 6, receiving component 507 has received attaching components foreach notch, and is then swept away by conveyor belt 216. Moveablecoupling mechanism 205 is now on its upstroke to retrieve anotherattaching component, attaching component 606. Since the distance betweenthe final attaching component (506) coupled to receiving component 508and the initial attaching component 606 being coupled to receivingcomponent 508 is generally greater than the distance between notches ina single receiving component, to permit the moveable coupling mechanism205 to operate at its periodic rate, transporting mechanism 210 mustaccelerate in FIG. 6. Specifically, transporting mechanism 210 mustchange to a third drive train motion having a second speed that is fastenough to align notch 519 with the moveable coupling mechanism 205 priorto it inserting attaching component 606 to receiving component 508.(Note that where receiving components 507 and 508 include a plurality ofnotches, attaching component (506) is the final attaching component of afirst plurality of attaching components to be attached to receivingcomponent 507. Similarly, attaching component 606 would be the initialattaching component of a second plurality of attaching components.)

At FIG. 7, transporting mechanism 210 is moving receiving component 508such that notch 519 will be aligned with the moveable coupling mechanism205. Moveable coupling mechanism 205 has retrieved attaching component606 and will insert it into notch 519 at the base of the down stroke.During this time, drive train 212, and thus transporting mechanism 210alternates from the third drive train motion at the second speed to thefirst drive train motion at the stair-stepped, intermittent speed. Thisfirst motion continues so long as attaching components are to beinserted into the notches of receiving component 508. Note that drivetrain 213 is now free to accelerate to permit transporting mechanism 209to return to the delivery module to retrieve another receivingcomponent.

Turning now to FIG. 8, illustrated therein is a more detailed side,elevation view of one embodiment of an assembly machine 200 inaccordance with the invention. From this view, details of the feeder201, the assembler 202, and the delivery module 203 can be seen.

As noted above, in one embodiment of the invention, each of theplurality of drive trains 212,213 comprises a variable speed servodriven loop. In FIG. 8, the variable speed servos 801,802 can moreclearly be seen. These variable speed servos 801,802 allow the drivetrain speed associated with either drive train 212,213 to change suchthat receiving components are delivered to the assembler 202 with aperiodic coupling rate of the moveable coupling mechanism 205 remainingconstant.

As with the drive trains, the moveable coupling mechanism 205 is alsodriven by a servo. Specifically, moveable coupling mechanism 205 isdriven by a moveable coupling mechanism servo 803 coupled to and capableof actuating the moveable coupling mechanism 205. As with the servosdriving the drive trains, the moveable coupling mechanism servo 803includes circuitry that acts as a moveable coupling mechanism servodetector to deliver the precise servo positions to the computer 204.Thus, the computer 204 is able to continually determine the moveablecoupling mechanism servo position.

The computer 204 is in communication with the transporting mechanismdetector 211, the variable speed servo 801 driving drive train 213, thevariable speed servo 802 driving drive train 212, and the moveablecoupling mechanism servo 803. From the transporting mechanism detector211, the computer 204 is able to detect the position of the transportingmechanisms. From the position of the variable speed servos 801,802, withknowledge of the length of the feeder table, the computer may determinethe feeder position of any of the transporting mechanisms. From themoveable coupling mechanism servo 803 and its moveable couplingmechanism servo detector, the computer 204 is able to detect theposition of the moveable coupling mechanism 205. Once all of this isdetermined or detected, the computer 204 is able to alter the speeds ofthe variable speed servos 801,802 so as to alter the speed of the drivetrains 212,213 and thus the drive train loops. In so doing the computer204 may alter, for example, the drive train speed of a second drivetrain loop such that the distance between a first transporting mechanismcoupled to the first drive train loop and components being driven by thesecond transporting mechanism is minimized prior to the delivery of thecomponents driven by the second transporting mechanism to the assembler202. In short, by detecting this information, the computer 204 iscapable of queueing components.

The computer 204 may also alter the drive train speed when serving asthe calibration device. Where the computer 204 does so to enable themoveable coupling mechanism to operate at a continuous periodic ratefrom receiving component to receiving component, the computer 204 variesthe drive train speed such that notches, or coupling regions, oncomponents driven by a first drive train and notches on componentsdriven by a second drive train exit the feeder table 221 at a constantrate.

Turning now to FIGS. 9 and 10, illustrated therein are a front elevationview and a rear elevation view of a feeder 201 in accordance with theinvention. From these views, the coupling of the drive trains to axels901,1001 can be seen. Drive train 212 is coupled to axel 901, whiledrive train 213 spins freely about axel 901. Conversely, drive train 213is coupled to axel 1001, while drive train 212 spins freely about axel1001. Belt 902 is coupled to variable speed servo 802, while belt 1002is coupled to variable speed servo 801. By varying either variable speedservo 801,802, the computer (204) can vary the speed of one drive train,drive train loop, drive train chain, and transporting mechanisms coupledthereto, without affecting the other's motion.

Turning now to FIG. 11, illustrated therein is a top, plan view of oneembodiment of a feeder 201 in accordance with the invention. From thisview, the receiving component guides 404,405,406 can more clearly beseen. Additionally, the drive trains 212,213 and their drive trainchains 1101,1102. Each drive train chain 1101,1102 has at least onetransporting mechanism 209,210 coupled thereto. In FIG. 11, transportingmechanism 209 is coupled to drive train chain 1101 and drive train 213,while transporting mechanism 210 is coupled to drive train chain 1102and drive train 212. The transporting mechanisms 209,210, and thus thedrive trains 212,213 are interlaced such that the first transportingmechanism 209 is followed sequentially by the second transportingmechanism 210 when the drive train chains 1101,1102 are in motion.

In the foregoing specification, specific embodiments of the presentinvention have been described. However, one of ordinary skill in the artappreciates that various modifications and changes can be made withoutdeparting from the scope of the present invention as set forth in theclaims below. Thus, while preferred embodiments of the invention havebeen illustrated and described, it is clear that the invention is not solimited. Numerous modifications, changes, variations, substitutions, andequivalents will occur to those skilled in the art without departingfrom the spirit and scope of the present invention as defined by thefollowing claims. Accordingly, the specification and figures are to beregarded in an illustrative rather than a restrictive sense, and allsuch modifications are intended to be included within the scope ofpresent invention.

1. An assembling machine, comprising: a. an assembler configured tocouple an attaching component to a receiving component, the assemblerhaving a moveable coupling mechanism configured to couple the attachingcomponent to the receiving component at a periodic coupling rate; and b.a feeder, the feeder comprising a plurality of drive trains, each drivetrain having at least one transporting mechanism coupled thereto, the atleast one transporting mechanism being configured to feed at least onereceiving component into the assembler; wherein a drive train speedassociated with one of the plurality of drive trains changes such thatthe periodic coupling rate remains constant between attachment of afirst attaching component with a first receiving component andattachment of a second attaching component with a second receivingcomponent; wherein the assembler comprises an insertion assembly,further wherein the attaching component comprises an insertingcomponent, the insertion assembly being configured to insert a pluralityof inserting components into the receiving component; wherein the feedercomprises a feeder table having a plurality of receiving componentguides, further wherein the at least one transporting mechanism isdisposed substantially perpendicularly to the plurality of receivingcomponent guides so as to move a plurality of receiving components alongthe plurality of receiving component guides at the drive train speed. 2.(canceled)
 3. (canceled)
 4. (canceled)
 5. (canceled)
 6. (canceled) 7.(canceled)
 8. (canceled)
 9. (canceled)
 10. The assembling machine ofclaim 1, wherein each drive train comprises a pair of chain driven loopshaving two transporting mechanisms coupled thereto.
 11. The assemblingmachine of claim 10, wherein the plurality of drive trains comprises afirst drive train interlaced with a second drive train such that whenthe first and second drive trains are in motion, a first transportingmechanism coupled to the first drive train is followed sequentially by asecond transporting member coupled to the second drive train.
 12. Theassembling machine of claim 11, wherein each of the first drive trainand the second drive train alternates between at least a first drivetrain motion having a stair-stepped intermittent speed, a second drivetrain motion having a first speed, and a third drive train motion havinga second speed.
 13. The assembling machine of claim 9, furthercomprising a delivery module configured to deliver receiving componentsto the plurality of receiving component guides at a periodic rate.
 14. Afeeder machine comprising: a. a feeder table; and b. at least two drivetrains, each of the at least two drive trains having at least onetransporting mechanism coupled thereto, the at least one transportingmechanism being configured to cause a graduated component to pass alongone side of the feeder table; wherein a drive train speed associatedwith one of the plurality of drive trains varies such that couplingregions on components driven by a first drive train and coupling regionson components driven by a second drive train exit the feeder table at aconstant rate.
 15. The feeder machine of claim 14, wherein each of theat least two drive trains has at least two transporting mechanismscoupled thereto, the at least two transporting mechanisms being disposedat substantially equidistant intervals along the each of the at leasttwo drive trains.
 16. The feeder machine of claim 15, wherein the atleast two drive trains comprise a first drive train and a second drivetrain, wherein the drive train speed associated with the second drivetrain varies so as to minimize the distance between the componentsdriven by a second transporting mechanism coupled to the second drivetrain and a first transporting mechanism coupled to the first drivetrain at least once when both the first transporting mechanism and thesecond transporting mechanism are transporting components.
 17. Thefeeder machine of claim 16, further comprising a transporting mechanismdetector capable of determining at least once the position of thetransporting mechanism along a drive train loop.
 18. The feeder machineof claim 17, wherein each of the at least two drive trains comprises apair of variable speed servo driven chains, further wherein the at leasttwo transporting mechanisms comprise rigid arms coupling the pair ofvariable speed servo driven trains.
 19. (canceled)
 20. (canceled) 21.(canceled)